Vibratory shakeout apparatus

ABSTRACT

A vibratory shakeout apparatus including a pair of suspended, parallelly spaced, horizontally disposed vibrating rails mounted at the end of a continuously traveling conveyor carrying a row of contiguous, flaskless sand molds containing cast articles therein is disclosed. The vibrating rails pierce each of the molds and engage the casting therein as the molds are moved into the apparatus and advance the oriented castings to an end position on the rails, separating the sand therefrom, where the castings are removed from the apparatus by a programmed mechanical handling device.

United States Patent [1 1 George et al.

[ VIBRATORY SHAKEOUT APPARATUS [75] Inventors: Michael D. George,Dayton;

Dominick J. Varano; George K. Bronson, both of Defiance, all of Ohio;Nelson L. Kitchin, Warren; William W. Rose, Jr., Ferndale, both of Mich.

[73] Assignee: General Motors Corporation,

' Detroit, Mich.

[22] Filed: Apr. 26, 1972 [21] App]. No.: 247,612

[52] U.S. Cl. 164/322, 164/187 [51] Int. Cl B22d 29/00 [58] Field 01Search 164/187, 131, 260,

[56] References Cited UNITED STATES PATENTS 3,627,020 12/1971 Taccone164/404 11 3,749,151 [451 July 31,1973

Primary Examiner-Gerald M. Forlenza Assistant m ri=J- O al!Attorney-Sidney Carter and Peter P. Kozak [57] ABSTRACT A vibratoryshakeout apparatus including a pair of suspended, parallelly spaced,horizontally disposed vibrating rails mounted at the end of acontinuously traveling conveyor carrying a row of contiguous, flasklesssand molds containing cast articles therein is disclosed. The vibratingrails pierce each of the molds and engage the casting therein as themolds are moved into the apparatus and advance the oriented castings toan end position on the rails, separating the sand therefrom, where thecastings are removed from the apparatus by a programmed mechanicalhandling device.

7 Claims, 4 Drawing Figures Patented Jul 31, 1973 3,749,151

2 Sheets-Sheet l Patented July 31, 1973 3,749,151

2 Sheets-Sheet 2 VIBRATORY SI-IAKEOUT APPARATUS This invention relatesto vibratory shakeout apparatus and, more particularly, to apparatus foruse in combination with a continuously traveling row of contiguous,flaskless sand molds wherein the castings are removed from the molds,the sand separated therefrom, and the castings conveyed to an endposition of the apparatus in an oriented position for removal therefrom.

In an effort to achieve increased automation of foundry castingprocesses, modern foundries are using automatic molding machines whichproduce a rectilinear row of flaskless sand molds. The use of suchautomatic apparatus permits the production of virtually finfree castingsof high dimensional accuracy in a continuous, automatic mold forming andcasting operation.

It has been conventional practice to remove cast articles from sandmolds by moving the molds from the pouring and cooling line onto ahorizontally disposed vibrating grate which breaks up the molds andvibrates the sand free from the castings with the sand falling throughthe openings in the grate to a collection bin below. In addition to theinherent objections of such systems, e.g., excessive noise and dustproduction, such shakeout apparatus are unsuitable for use with anautomated mold forming and casting process. That is, these systems oftenresult in random breaking of the casting or of its gating system. In anautomated operation, it is desirable that the gating system remainintact for positioning of the casting in an automatic shearingapparatus. Furthermore, since highly dimensionally accurate castings areproduced in anautomated operation, to preserve casting quality it isdesirable that the castings not contact the shakeout apparatus. Stillfurther, prior art systems moved the castings to the end of the shakeoutbed in a completely random and disoriented manner. In an automatedcasting process, it is necessary that the castings be removed from themolds and conveyed through the shakeout system in an oriented fashionfor further processing.

Accordingly, it is the principal object of this invention to provide animproved, automatic shakeout apparatus for use in combination with anautomatic mold forming and casting line which sequentially removes thecastings from the molds, separates the sand therefrom, and advances thecastings to the end of the apparatus for removal from the casting line.

It is another object of our invention to provide automatic shakeoutapparatus wherein the castings are removed from the molds and advancedin an oriented position to a position at the end of the apparatus forremoval by an automatic mechanical handling device without the usablecast portion of the cast article contacting the apparatus.

It is a further object of our invention to provide an improved shakeoutapparatus which automatically con trols the movement of the castingsfrom the mold line along the apparatus to the removal position at theend of the apparatus.

These and other objects of our invention are accomplished in accordancewith the preferred embodiment by providing a pair of suspended,parallelly spaced, horizontally disposed rails mounted at the end of acontinuously traveling row of contiguous, flaskless type sand moldscontaining cast articles therein and having ends opposite the directionof movement of the molds adapted for piercing each of the oncoming moldscarried by the conveyor into engagement with the ends and forsupportingly engaging each of the castings. The rails are preferablyvibrated in a direction inclined to the horizontal and away from theoncoming molds to facilitate piercing of the molds and to advance thesand-bearing castings to the opposite end of the rails, separating thesand therefrom, where the castings are removed by a programmedmechanical handling device. The rails preferably include a series ofmechanical stops responsive to the positions of the castings on therails to control their movement therealong.

Other objects and advantages of our invention will be apparent from thefollowing detailed description, reference being had to the accompanyingdrawings of which: I

FIG. 1 is a schematic side elevational view of an automated mold formingand casting process;

FIG. 2 is a schematic cross-sectional side view of the mold formingapparatus shown in FIG. 1;

FIG. 3 is a perspective view of the mold exit and of the mold formingapparatus shown in FIG. 1 with a mold partially broken away; and

FIG. 4 is a perspective view of the apparatus embodying this inventionpositioned at the end of the casting line as shown in FIG. 1 with a moldpartially broken away.

Referring now to the drawings and particularly to FIG. 1, there is shownan automated mold forming and casting process to which our invention isparticularly applicable. At the start of the mold line is an automaticmold forming apparatus 10, having a sand delivery bin 12 thereabove,producing flaskless type sand molds 14. As shown in FIG. 2, the molds 14are formed by compressing foundry sand from a hopper 16 connected to themolding chamber between a tiltable front pattern plate 18 and a rearpattern plate 20 mounted on a hydraulic piston 22. After forming of themold 14 the front pattern plate 18 is stripped from the mold l4 andtilted up to a horizontal position. The rear pattern plate 20 thenconveys the mold linearly forward out of the apparatus on a bed 24 incontinuation with the mold forming apparatus 10 bringing the mold 14into contact with the previously formed mold 14' on bed 24. Thereafter,the rear pattern plate pushes the entire line of molds 14 linearlyforward a distance equal to the thickness of the mold 14, thus forming arectilinear line of molds in a continuous mold forming process.

As may be seen from FIGS. 2 and 3, the end surfaces of the molds carryimpressions of the pattern such that mold cavities 26 are formed betweenthe molds when closed with each other. In accordance with conventionalfoundry practice the mold cavity includes a downsprue 28 and runners 30communicating with the article forming cavity 32.

As each mold is formed, the mold line is pushed forward on the bed 24and at a given position along the line the mold cavities 26 of the molds14 are sequentially filled with molten metal from a bottom pour ladle 34positioned above the molds 14. After pouring, the molds are pushed ontoa continuously linearly traveling conveyor 36 in direct continuationwith the bed 24 which is electrically driven in synchronization with thehydraulic piston 22. The molds cool while traveling on the conveyor 36to form solidified cast articles therein. Mounted in a stationaryposition at the end of the conveyor is the vibratory shakeout apparatus38 embodying this invention, which is followed on the mold line by amechanical handling device 40, as hereinafter more fully explained.

' Referring now to FIG. 4, the vibratory shakeout apparatus 38 includesa pair of suspended, substantially parallelly spaced, horizontallydisposed rails 42 having ends 44 extending in a direction opposite thelinear path of movement of the molds 14 on the continuously travelingconveyor 36. Below the rails 42 and connected thereto by means of bars46 and 48, is a motor 50 for vibrating the rails. In accordance with thepresent invention the rails 42 are continuously vibrated in a directioninclined to the horizontal and away from the oncoming molds, as shown bythe arrow 52 in FIG. 4. It will be recognized that our invention is notlimited to any particular vibrating means, its position in relation tothe rails, or manner of connection with the rails. We have found that anelectro-mechanical natural frequency vibratory feeder drive motor havinga stroke infinitely variable from zero to five-sixteenths inch is asuitable drive means. When separating ductile iron castings from sandmolds having a green strength of about 22 psi and a hot strength over 75psi, the rails are preferably vibrated at an angle 60 inclined to thehorizontal with a 5/16 inch stroke away from the oncoming molds;however, these parameters may be varied depending on the metal beingcast, the type of sand used and its adherency to the castings, and thedesired speed of movement of the castings along the rails. For example,at lower angles of attack such as 45, the castings move at a greaterrate along the rails than at a 60 angle of attack.

Positioned along the rails and on the sides thereof are a primary stopmechanism 54 and a secondary stop mechanism 56 used to control themovement of the castings along the rails 42. Mounted at the ends of therails 42 opposite ends 44 is a holder 58 for holding the castings forpick-up by the mechanical handling device In operation, the filled molds14 travel along conveyor 36 in a linear path toward the shakeoutapparatus 38 in a continuous mold forming and casting process. At thestart of the shakeout operation when the apparatus is free of castingsthe primary stop 54 is open, i.e., in its down position, and thesecondary stop is closed, i.e., in its up position, as shown in FIG. 4.As the molds 14 are carried into the apparatus, the ends 44 of thevibrating rails pierce the molds in a forward and upward directionbreaking up the sand molds thereby. When the mold has advancedsufficiently, the ends 44 supportingly engage the cast article 37 atspaced, horizontally disposed portions 60 whereby the cast article 37becomes suspended on the rails by portions 60. The particular portion ofthe cast article engaged by ends 44 is not critical, and it may compriseeither a portion of the usable casting itself or the gating system maybe so designed to provide spaced, horizontally disposed cast arms forengagement by the rails. Since it is often desirable to prevent contactof the rails with the usable cast portion or since intricate castingsmay not include suitable engaging sections, the latter method ispreferred.

Once supported on the rails 42, the cast article advances toward theholder 58 as a result of the vibratory motion of the rails with the sandadhering to the cast article being removed by vibration. The sandremoved from the vibrating castings and that broken free on initialpiercing of the molds falls below the apparatus into bins, a chute, oronto a conveyor (not shown) for collection and reuse. The primary stop54 remains open and the secondary stop 56 closed until the first castingcontacts the secondary stop 56. The primary stop 54 then closes and thesecondary stop 56 then opens, providing the holder 58 is empty. The castarticle 37 then advances into the holder 58 where it is removed from theapparatus 38 by a programmed mechanical handling device 40 andtransferred automatically for subsequent processing. For example, thecast article may be immediately transferred to apparatus for removingthe gating system from the usable cast portion.

As one cast article moves along the rails toward the holder 58, thepiercing ends 44 of the rails 42 engage the casting in the followingmold in a continuous, sequential shakeout operation such that there is acontinuous flow of castings along the rails 42 from the piercing ends 44to the holder 58, as illustrated in FIG. 4. It will be recognized thatthe particular sequence of movement of the castings along the rails maybe adapted to particular operations. For example, several castings maybe backed-up behind the secondary stop 56 before the primary stop 54closes after which the secondary stop 56 opens allowing only the castingin contact therewith to advance into the holder 58. Further, the primarystop 54 may be operatively connected to the conveyor drive motor. totemporarily stop movement of the molds to allow for clearing of theshakeout apparatus should an excessive number of castings be suspendedbehind the primary stop.

One of the features of our invention is the ability to remove the castarticles from the molds, separate the sand therefrom, and advance thecast articles to a position for removal by a programmed device in anoriented position. That is, in an automated operation it is highlydesirable that the cast articles move in an oriented rather than randomfashion whereby the articles may be automatically transferred tosuccessive operations comprising devices designated to accept thearticles in a predetermined orientation. As may be seen from FIG. 4, thevibrating rails 42 engage the cast article 37 at portions 60 andseparate the sand therefrom thus supporting the cast article in the sameorientation as within the mold. As the cast article 37 advances alongthe rails 42 and into the holder 58 its orientation remains the same.Accordingly, the cast article may be removed from the holder 58 by themechanical handling device 40 programmed to grasp the castingsin itsgiven orientation.

Although our invention has been described in terms of certain preferredembodiments, it will be recognized by those skilled in the art thatother forms may be adopted within the scope of the invention.

We claim:

1. In combination with a row of contiguous, flaskless type sand moldscontaining cast articles therein mounted on a continuously travelingconveyor adapted for movement along a linear path, apparatus forseparating said cast articles from said molds comprising at least onesuspended, substantially horizontally disposed rail mounted at the endof said row along said linear path, the end of said rail opposite thedirection of movement of said row being adapted for piercing each ofsaid molds as each mold is carried by said conveyor into engagement withsaid end and for supportingly engaging each of said cast articles, andmeans for vibrating said rail in a direction inclined to the horizontalto facilitate piercing of said molds and to advance the sand-bearingcast articles from the piercing end of said rail to the opposite endthereof and to separate the sand therefrom.

2. In combination with a row of contiguous, flaskless type sand moldscontaining cast articles therein mounted on a continuously travelingconveyor adapted for movement along a linear path, apparatus forseparating said cast articles from said molds comprising a pair ofsuspended, substantially parallelly spaced, horizontally disposed railsmounted at the end of said row along said linear path, the ends of saidrails opposite the direction of movement of said row being adapted forpiercing each of said molds as each mold is carried by said conveyorinto engagement with said ends and for supportingly engaging each ofsaid cast articles, and means for vibrating said rails in a directioninclined to the horizontal to facilitate piercing of said molds and toadvance the sand-bearing cast articles from the piercing ends of saidrails to the opposite end thereof and to separate the sand therefrom.

3. In combination with a row of contiguous, flaskless type sand moldscontaining cast articles therein mounted on a continuously travelingconveyor adapted for movement along a linear path, apparatus forseparating said cast articles from said molds comprising a pair ofsuspended, substantially parallelly spaced, horizontally disposed railsmounted at the end of said row along said linear path, the ends of saidrails opposite the direction of movement of said row being adapted forpiercing each of said molds as each mold is carried by said conveyorinto engagement with said ends and for supportingly engaging each ofsaid cast articles, and means for vibrating said rails in a directioninclined to the horizontal and away from the oncoming molds tofacilitate piercing of said molds and to advance the sand-bearing castarticles from the piercing ends of said rails to the opposite endthereof and to separate the sand therefrom.

4. In combination with a row of contiguous, flaskless type sand moldscontaining cast articles therein mounted on a continuously travelingconveyor adapted for movement along a linear path, apparatus forseparating said cast articles from said molds comprising a pair ofsuspended, substantially parallelly spaced, horizontally disposed railsmounted at the end of said row along said linear path, the ends of saidrails opposite the direction of movement of said row being adapted forpiercing each of said molds as each mold is carried by said conveyorinto engagement with said ends and for supportingly engaging each ofsaid cast articles, and means for vibrating said rails in a directioninclined to the horizontal to facilitate piercing of said molds and toadvance the sand-bearing cast articles from the piercing ends of saidrails to the opposite end thereof in an orientation substantially thesame as within the molds and to separate the sand therefrom, the ends ofsaid rails opposite the piercing ends being adapted to receive and holdthe cast articles in an orientation substantially the same as within themolds.

5. In combination with a row of contiguous, flaskless type sand moldscontaining cast articles therein mounted on a continuously travelingconveyor adapted for movement along a linear path, apparatus forseparating said cast articles from said molds comprising a pair ofsuspended, substantially parallelly spaced, horizontally disposed railsmounted at the end of said row along said linear path, the ends of saidrails opposite the direction of movement of said row being adapted forpiercing each of said molds as each mold is carried by said conveyorinto engagement with said ends and for supportingly engaging each ofsaid cast articles, and means for vibrating said rails in a directioninclined to the horizontal and away from the oncoming molds tofacilitate piercing of said molds and to advance the sand-bearing castarticles from the piercing ends of said rails to the opposite endthereof in an orientation substantially the same as within the molds andto separate the sand therefrom, the ends of said rails opposite thepiercing ends being adapted to receive and hold the cast articles in anorientation substantially the same as within the molds.

6. In combination with a row of contiguous, flaskless type sand moldscontaining cast articles therein mounted on a continuously travelingconveyor adapted for movement along a linear path, apparatus forsequentially separating said cast articles from said molds comprising apair of suspended, substantially parallelly spaced, horizontallydisposed rails mounted at the end of said row along said linear path,the ends of said rails opposite the direction of movement of said rowbeing adapted for piercing each of said molds as each mold is carried bysaid conveyor into engagement with said ends and for supportinglyengaging each of said cast articles, the ends of said rails opposite thepiercing ends being adapted to receive and hold said cast articles;means for vibrating said rails in a direction inclined to the horizontalto facilitate piercing of said molds and to advance the sand-bearingcast articles from the piercing ends of said rails to the opposite endthereof and to separate the sand therefrom; and means for stopping theadvance of said cast articles along said rails and for sequentiallyreleasing each of said cast articles in contact therewith for advance tosaid ends adapted to hold said cast articles when said ends are free ofcast articles.

7. In combination with a row of contiguous, flaskless type sand moldscontaining cast articles therein mounted on a continuously travelingconveyor adapted for movement along a linear path, apparatus forseparating said cast articles from said molds comprising a pair ofsuspended, substantially parallelly spaced, horizontally disposed railsmounted at the end of said row along said linear path, the ends of saidrails opposite the direction of movement of said row being adapted forpiercing each of said molds as each mold is carried by said conveyorinto engagement with said ends and for supportingly engaging each ofsaid cast articles, and means for vibrating said rails in a direction 45to 60 inclined to the horizontal to facilitate piercing of said moldsand to advance the sand-bearing cast articles from the piercing ends ofsaid rails to the opposite end thereof and to separate the sandtherefrom.

a a: a s a

1. In combination with a row of contiguous, flaskless type sand moldscontaining cast articles therein mounted on a continuously travelingconveyor adapted for movement along a linear path, apparatus forseparating said cast articles from said molds comprising at least onesuspended, substantially horizontally disposed rail mounted at the endof said row along said linear path, the end of said rail opposite thedirection of movement of said row being adapted for piercing each ofsaid molds as each mold is carried by said conveyor into engagement withsaid end and for supportingly engaging each of said cast articles, andmeans for vibrating said rail in a direction inclined to the horizontalto facilitate piercing of said molds and to advance the sand-bearingcast articles from the piercing end of said rail to the opposite endthereof and to separate the sand therefrom.
 2. In combination with a rowof contiguous, flaskless type sand molds containing cast articlestherein mounted on a continuously traveling conveyor adapted formovement along a linear path, apparatus for separating said castarticles from said molds comprising a pair of suspended, substantiallyparallelly spaced, horizontally disposed rails mounted at the end ofsaid row along said linear path, the ends of said rails opposite thedirection of movement of said row being adapted for piercing each ofsaid molds as each mold is carried by said conveyor into engagement withsaid ends and for supportingly engaging each of said cast articles, andmeans for vibrating said rails in a direction inclined to the horizontalto facilitate piercing of said molds and to advance the sand-bearingcast articles from tHe piercing ends of said rails to the opposite endthereof and to separate the sand therefrom.
 3. In combination with a rowof contiguous, flaskless type sand molds containing cast articlestherein mounted on a continuously traveling conveyor adapted formovement along a linear path, apparatus for separating said castarticles from said molds comprising a pair of suspended, substantiallyparallelly spaced, horizontally disposed rails mounted at the end ofsaid row along said linear path, the ends of said rails opposite thedirection of movement of said row being adapted for piercing each ofsaid molds as each mold is carried by said conveyor into engagement withsaid ends and for supportingly engaging each of said cast articles, andmeans for vibrating said rails in a direction inclined to the horizontaland away from the oncoming molds to facilitate piercing of said moldsand to advance the sand-bearing cast articles from the piercing ends ofsaid rails to the opposite end thereof and to separate the sandtherefrom.
 4. In combination with a row of contiguous, flaskless typesand molds containing cast articles therein mounted on a continuouslytraveling conveyor adapted for movement along a linear path, apparatusfor separating said cast articles from said molds comprising a pair ofsuspended, substantially parallelly spaced, horizontally disposed railsmounted at the end of said row along said linear path, the ends of saidrails opposite the direction of movement of said row being adapted forpiercing each of said molds as each mold is carried by said conveyorinto engagement with said ends and for supportingly engaging each ofsaid cast articles, and means for vibrating said rails in a directioninclined to the horizontal to facilitate piercing of said molds and toadvance the sand-bearing cast articles from the piercing ends of saidrails to the opposite end thereof in an orientation substantially thesame as within the molds and to separate the sand therefrom, the ends ofsaid rails opposite the piercing ends being adapted to receive and holdthe cast articles in an orientation substantially the same as within themolds.
 5. In combination with a row of contiguous, flaskless type sandmolds containing cast articles therein mounted on a continuouslytraveling conveyor adapted for movement along a linear path, apparatusfor separating said cast articles from said molds comprising a pair ofsuspended, substantially parallelly spaced, horizontally disposed railsmounted at the end of said row along said linear path, the ends of saidrails opposite the direction of movement of said row being adapted forpiercing each of said molds as each mold is carried by said conveyorinto engagement with said ends and for supportingly engaging each ofsaid cast articles, and means for vibrating said rails in a directioninclined to the horizontal and away from the oncoming molds tofacilitate piercing of said molds and to advance the sand-bearing castarticles from the piercing ends of said rails to the opposite endthereof in an orientation substantially the same as within the molds andto separate the sand therefrom, the ends of said rails opposite thepiercing ends being adapted to receive and hold the cast articles in anorientation substantially the same as within the molds.
 6. Incombination with a row of contiguous, flaskless type sand moldscontaining cast articles therein mounted on a continuously travelingconveyor adapted for movement along a linear path, apparatus forsequentially separating said cast articles from said molds comprising apair of suspended, substantially parallelly spaced, horizontallydisposed rails mounted at the end of said row along said linear path,the ends of said rails opposite the direction of movement of said rowbeing adapted for piercing each of said molds as each mold is carried bysaid conveyor into engagement with said ends and for supportinglyengaging each of said cast articles, the ends of said rails opposite thepiercing ends beiNg adapted to receive and hold said cast articles;means for vibrating said rails in a direction inclined to the horizontalto facilitate piercing of said molds and to advance the sand-bearingcast articles from the piercing ends of said rails to the opposite endthereof and to separate the sand therefrom; and means for stopping theadvance of said cast articles along said rails and for sequentiallyreleasing each of said cast articles in contact therewith for advance tosaid ends adapted to hold said cast articles when said ends are free ofcast articles.
 7. In combination with a row of contiguous, flasklesstype sand molds containing cast articles therein mounted on acontinuously traveling conveyor adapted for movement along a linearpath, apparatus for separating said cast articles from said moldscomprising a pair of suspended, substantially parallelly spaced,horizontally disposed rails mounted at the end of said row along saidlinear path, the ends of said rails opposite the direction of movementof said row being adapted for piercing each of said molds as each moldis carried by said conveyor into engagement with said ends and forsupportingly engaging each of said cast articles, and means forvibrating said rails in a direction 45* to 60* inclined to thehorizontal to facilitate piercing of said molds and to advance thesand-bearing cast articles from the piercing ends of said rails to theopposite end thereof and to separate the sand therefrom.